Reclaiming and utilizing discarded and newly formed coke breeze, coal fines, and blast furnace revert materials, and related methods

ABSTRACT

A method and a solid fuel product, such as briquettes and pellets, comprising carbon fines, in the form of heretofore discardable coke breeze and/or coal fines and/or revert materials, bound together chemically into smaller pieces to substantially prevent degradation and which constitutes a source of high heat without creating significant pollution or smoke.

CONTINUITY

This application is a continuation of my U.S. patent application Ser. No. 08/184,099, which was filed Jan. 21, 1994, now U.S. Pat. No. 5,453,103.

FIELD OF INVENTION

The present invention relates generally to coke breeze, coal fines, and blast furnace revert materials, and, more particularly, to the elimination of coke breeze, coal fines, and blast furnace revert materials, as discarded, pollution causing by-products and the processes and products by which these materials are constructively utilized.

BACKGROUND

In the past, coke breeze (produced as a by-product of coke production), coal fines (produced as a by-product of coal mining per se) and blast furnace revert materials (produced as a by-product of steel production) have been routinely discarded, in large quantities, creating a source of pollution and presenting a fire hazard which continues for decades.

Coke is a pure carbon, high heat, clean burning fuel used primarily in steel-making blast furnaces and other industrial applications. It is made from metallurgical grade coal which is heated in the absence of air in large ovens. Volatile matter is driven off the coal, leaving pure carbon. Small pieces of coke, known as coke breeze or coke fines, are a waste product of the coke-making process. Coke breeze has, for years, been accumulated as a waste product from the above-described process by which coke is manufactured. Stockpiles of waste coke breeze are unsightly and constitute an ever enlarging source of environmental pollution.

Coke breeze per se is not suitable for use in blast furnaces because of its small size and, consequently, is of little or no value to the steel manufacturer.

Coal fines, similarly, are small coal particles ranging from less than one quarter of one inch in diameter to dust size which are created during coal mining operations. Coal fines are available in abundance worldwide and have historically been simply accumulated in piles at various locations, presenting a disposal problem for coal producers as well as a fire hazard. Typically, coal fines are disposed of at or near the mine site in piles or trenches, creating actual and potential environmental problems.

Blast furnace revert material comprises mill scale, dust and sludge derived from the production of steel, which contains a large amount of non-oxidized combustible particles or pieces. This material also has over the years been discarded and stored as ugly piles of useless material which presents environmental and fire hazard problems, both actual and potential.

Disposal of coke breeze, coal fines, and revert material has been a long-standing problem of substantial proportions. Similarly, providing a useful purpose and useful form for coke breeze, coal fine, and/or revert materials has been a major long-term problem for which, prior to the present invention, a satisfactory solution has not been found. Prior attempts to place coke breeze, coal fines, and/or revert materials in a solid form, such as briquettes, has been largely unsuccessful because the product does not adequately bind and is instable, disintegrating or retrogressively degrading back into small, fine particles during storage and handling prior to use.

BRIEF SUMMARY AND OBJECTS OF THE PRESENT INVENTION

In brief summary, the present invention overcomes or substantially alleviates the above-identified problems of the prior art. A method and solid product, in the form of briquettes and/or pellets, are provided comprised of coke breeze and/or coal fines and/or revert materials bound together to substantially prevent degradation into smaller pieces. The briquettes provide a source of fuel and heat, which is clean burning, and substantially smokeless and which alleviates a long-term, existing and on-going pollution problem.

With the foregoing in mind, it is a primary object of the present invention to overcome or substantially alleviate all or some of the problems of the prior art mentioned above.

Another object of significance is the provision of a novel method and a relatively large solid product comprised of non-degradable coke breeze and/or coal fine and/or revert materials substantially bound together so that the solid nature of the product does not degrade with time.

A further important object is the provision of a novel method of producing a relatively large solid fuel product and the fuel product itself, which is clean burning and substantially smokeless.

An additional dominant object is to provide a method and relatively large, solid product which does not degrade and which alleviates an existing on-going source of pollution.

It is a further principal object of the present invention to provide a method and relatively large solid product derived from recycled waste material produced in the course of coal mining, coke production operations, and/or steel production by which a high value fuel product, which is commercially viable, is obtained.

An additional valuable object is the provision of briquettes or pellets derived from coke breeze and/or coal fines and/or revert materials suitable for many industrial and non-industrial applications including steel making blast furnaces and household fireplaces and woodburning stoves.

It is a further dominant object according to the present invention to provide a solid fuel derived from waste materials which is durable, is clean burning, retains its BTU heat value, is economical to produce, and is suitable for a variety of industrial and non-industrial purposes.

It is a further object of the present invention to provide a novel method and relatively large solid product formed by mixing of coke breeze and/or coal fines and/or revert materials with a novel binding agent.

A further significant object is the provision of a recycle method and recycle relatively large solid product which eliminates or alleviates a long-standing environmental problem, transforming waste material into a viable fuel product.

A further paramount object of the present invention is the provision of a novel method and solid fuel product which, when burned in stoves and fireplaces does not cause appreciable air pollution.

A further object of the present invention is the provision of a novel method and solid product comprising coke breeze and/or coal fines and/or revert materials bound together such that neither the coke breeze nor the coal fines nor the revert materials nor the binding agent releases harmful emissions during combustion or incineration.

A further valuable object of the present invention is the provision of a novel method and unique solid fuel product comprising coke breeze and/or coal fines and/or revert materials bound together in such a way that utilization thereof industrially, such as in a blast furnace, or otherwise does not produce emissions in violation of permissible limits.

It is a further object of the present invention to provide a novel method and unique solid fuel product from raw materials heretofore treated as waste which produces little ash and essentially no creosote during combustion or incineration.

A further primary object is the provision of a novel method and unique solid fuel product formed from waste which has a high BTU value.

These and other objects and features of the present invention will be apparent from the detailed description taken with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a flow chart of one process by which a solid, relatively large fuel product, in the form of briquettes or pellets, for example, is formed in accordance with the principals of the present invention; and

FIG. 2 is another flow chart of another process by which a solid, relatively large fuel product is formed in accordance with the principles of the present invention.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS EXAMPLE 1

With reference to FIG. 1, two hundred pounds (200 lbs.) of wet coal fines were introduced into a blender. The water content was measured at thirty percent (30%) by weight. Thus, the mix was relatively dry. The material was blended until the coal fines were evenly distributed in the water. Mixing continued for approximately ten (10) minutes is normally suitable. An ample amount of carbonic acid is derived from the coal to establish a pH value which accommodates the binding effect described below.

A hygroscopic solvent (methyl ethyl ketone) into which a ten percent (10%) by volume styrene polymer resin had been dissolved, was then added to the blender at the level of seven percent (7%) by weight. The material in the blender was blended until even distribution of the doped solvent throughout the coal fines and water mixture was achieved. About ten (10) minutes is usually suitable.

A twelve percent (12%) by weight polyvinyl acetate and water emulsion was then added to the mixture and blended until the mixture was homogenous. The resulting mixtures were then pressed into briquettes, using a conventional briquette machine at an injection pressure of 3,000 psig.

EXAMPLE 2

With continued reference to FIG. 1, the above-described process was repeated with dry coke breeze. A lesser amount of water was needed to create a coke breeze-water mixture from which solid briquettes can be derived.

Approximately ten percent (10%) water by weight was added to the dry coke breeze and mixed until homogenous (on the order of ten minutes). The steps as described in Example 1 above were then repeated and hard briquettes were formed in a briquette machine at the end of the injection pressure step.

Theory

While it is not certain, perhaps the present invention polymerizes the carbon particles contained in the coke breeze and coal fines waste materials into a new long chain polymer compound, yet unidentified, which provides structurally superior briquette or pellet strength over the prior art. It is known that oxides of carbon will hydrolyze in water. This reaction leaves free carboxyl ions present in the compound.

Introduction of the doped methyl ethyl ketone is believed to allow for attachment of the styrene polymer to the free carbon ions by exchange of the polymer for water which is absorbed into the solvent.

In the next phase, polyvinyl acetate is introduced into the slurry. Again the presence of the methyl ethyl ketone acts as a catalyst to remove and allow the styrene to react to the polyvinyl acetate. That an exothermic reaction was taking place was evidenced by the rise in temperature of approximately 15° F. above ambient during the time that the briquettes were curing.

The resulting solid fuel product, such as briquettes and/or pellets, is structurally stable and does not retrogress into fine particles during storage and handling. The solid fuel product is bound reliably together and constitutes high BTU fuel for industrial and residential which does not materially pollute the air because it is clean burning.

EXAMPLE 3

With reference to FIG. 2, equal amounts of blast furnace dust and blast furnace sludge were combined with hydrochloric acid in water. The dust and sludge, respectively comprised thirty-nine percent (39%) by weight of total ingredients of the ultimate mixture, exclusive of water. This ratio was arbitrarily chosen. Hydrochloric acid comprised four percent (4%) and a quantity sufficient of water, usually eight percent (8%) by weight was added. This initial mixture was blended for on the order of ten (10) minutes.

The hydrochloric acid adjusts the pH to accommodate the required binding of the particles of revert material by which an anti-degradable solid fuel is obtained.

Coke breeze in the amount of ten percent (10%) by weight was added to the initial mixture and combination mixed in the blender for an additional two (2) minutes to homogeneously disperse the coke breeze. While not essential to a solid fuel product for residential and like uses, the coke breeze does as a spline to hold the ultimate product together and accommodates use as a high temperature source for use in blast furnaces. For use other than in blast furnaces and the like, coal fines can be used in lieu of coke breeze.

Thereafter, a conditioner in the amount of three percent (3%) by weight was added to the twice blended mixture to attach acrylonitrile polymer to the material of the mix and blending continued for an addition five (5) minutes. Methyl ethyl ketone is combined with the acrylonitrile as a solvent carrier to prevent premature setting and to act as a cleaner. Homopolymer in the amount of five percent (5%) by weight was next added and mixing continued for five (5) more minutes. The homopolymer acts with the acrylonitrile to enhance binding of the carbon-containing materials into an anti-degradable solid fuel product.

The resulting briquette material is continuously mixed as it is fed in a conventional fashion to a standard briquette machine where the briquettes are formed under pressure.

The briquettes do not deteriorate with time and are clean burning in stoves, fireplaces, and blast furnaces.

The amount of water added to the mixture may be varied depending upon the moisture content of the respective material from which the briquette mix is formed. While this and other examples show a mix of materials to be reclaimed, it is to be appreciated that any one of the discarded materials can be used exclusively or, in the alternative, in conjunction with one or more other carbon-bearing discarded materials in the formation of high heat and low pollution briquettes or the like, which do not degrade with time.

The presently preferred homopolymer material is 32-024 homomer Polyvinyl acetate emulsion, available from National Starch and Adhesive. The presently preferred conditioner is acrylonitrile polymer retained in a prolonged fluid state by methyl ethyl ketone. Acrylonitrile polymer is available from Polymerland and Ballard Medical Products. Technical grade methyl ethyl ketone, available from Dice Chemical Co. and Thatcher Chemical Co., is preferred. Ninety percent (90%) by weight methyl ethyl ketone and ten percent (10%) by weight acrylonitrile polymer is suitable, although these amounts can be varied.

The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. 

What is claimed and desired to be secured by Letters Patent is:
 1. A method of forming a solid blast furnace fuel product which does not risk generation or release of a hazardous substance, comprising the steps of;(a) creating a water lean well mixed mixture of coke breeze and/or coal fines and water to form free carboxy ions on the surface of the carbon particles; (b) dissolving styrene polymer resin in a hygroscopic solvent; (c) combining the dissolved styrene resin in the water and coke breeze and/or coal fines mixture and well mixing the combination, to react the surface with the mixture of hygroscopic solvent and styrene to form free carbon ions by exchange of the styrene polymer resin in the hygroscopic solvent for water; (d) emulsifying polyvinyl acetate in water, adding the emulsion to the combination of set (c) and well mixing the resultant to react the polyvinyl acetate with the styrene resin; (e) subdividing the resultant of step (d) into segments and applying pressure to each segment to create hard, non-degradable solid fuel objects.
 2. A method according to claim 1 wherein the hygroscopic agent comprises methyl ethyl ketone.
 3. A method according to claim 1 wherein the water of step (a) is on the order of thirty percent (30%) by weight.
 4. A method according to claim 1 wherein all of the mixing comprises mechanical mixing.
 5. A method according to claim 1 wherein the dissolved styrene polymer resin produced by step (b) is combined in an amount on the order of seven percent (7%) by weight of the total combination in step (c).
 6. A method according to claim 1 wherein the polyvinyl acetate emulsion produced by step (e) is added in an amount on the order of twelve percent (12%) by weight of the total resultant of step (e).
 7. A method according to claim 1 wherein carbon particles in the form of coke breeze and/or coke fines are bonded together by polymerization of the styrene polymer.
 8. A method according to claim 7 wherein the polymerization comprises molecular attachment of the styrene polymer to carbon ions.
 9. A method according to claim 7 wherein the hygroscopic agent acts as a catalyst to remove and allow the styrene polymer to react with polyvinyl acetate.
 10. A method according to claim 1 wherein the pressure of step (f) is on the order of about 3,000 psig.
 11. A method of forming solid fuel objects comprising the steps of blending a solution of a hygroscopic solution and styrene with an aqueous composition comprising coke breeze and/or coal fines and reacting the styrene with free carbon ions to form a long chain polymer and subjecting quantities of the styrene and aqueous composition to high compressive force to create solid fuel objects.
 12. A method of binding carbon particles in the form of coke breeze and/or coal fines together into fuel object for blast furnace utilization comprising the steps of creating available carbon ionic bonding sites at the carbon particles by application of a hygroscopic solvent to an aqueous composition comprising the carbon particles, bonding styrene polymer to the carbon ionic bonding site and reacting the aqueous composition and styrene polymer in segregated quantities at a high compressive force to create ionically bound non-degradable fuel objects.
 13. A low pollution, high heat object found of discardable carbon particles comprising:a primary body of compressed coke breeze and/or coal frees and/or revert material comprising a long chain polymer comprising polymeric binder chemically reacted to carbon attachment sites on the carbon particles which body does not emit more than negligible amount of pollutants or hazardous substances when the fuel body is oxidized in a blast furnace.
 14. A low pollution, high heat fuel in the form of solid objects comprising a compressed quantity of coke breeze and/or coal fines and/or revert material comprising molecular carbon attachment sites ionically polymerized together against degradation by a long chain polymer compound comprising styrene, which fuel does not emit more than a negligible amount of pollutants or emissions or production of harmful substances when the object is oxidized in a blast furnace.
 15. A method of producing a non-toxic non-hazardous solid briquette and/or pellet fuel from fine particles comprising carbon comprising the steps of:(a) creating an aqueous mixture comprising carbon fines to hydrolyze the carbon thereby producing free carboxyl ions; (b) treating the aqueous mixture with a hygroscopic solvent comprising a styrene polymer resin to attach the styrene polymer to free carbon ions and with an aqueous composition comprising polyvinyl acetate, the hygroscopic solvent functioning as a catalyst to allow the styrene to react to the polyvinyl acetate; (c) applying pressure to quantities of the resultant from step (b) whereby polymerized briquettes and/or pellets are formed which do not degrade or destruct into pieces over time and which provide high heat, low pollution, and non-hazardous, nontoxic by-products when oxidized in a blast furnace.
 16. A solid fuel object comprising the reaction product ofcompressed combustible material comprising carbon selected from the group consisting of revert materials, coke breeze, and coal fines; an anti-degradable binder interconnecting the compressed combustible material and comprising a mixture of acrylonitrile and homopolymer.
 17. A method of binding carbon particles in the form of coke breeze and/or coal fines and/or revert material together into fuel objects for oxidation in a blast furnace comprising the steps of creating available carbon ionic bonding sites at the carbon particles in an aqueous composition comprising the carbon particles reacting a non-phenolic polymeric substance to the carbon ionic bonding sites in an environment free from materials from which hazardous substances are obtained and subjecting the aqueous composition and polymer in segregated quantifies to a relatively high compressive force to create ionically bound non-degradable fuel objects.
 18. A low pollution, high heat fuel object for oxidation in a blast furnace formed of discardable carbon particles comprising:a primary body of compressed coke breeze and/or coal fines and/or revert material comprising molecular carbon attachment sites polymerized together against blast furnace degradation by a long chain polymer free of phenolic material and isocyanate which object does not emit more than negligible amounts of pollutants when the fuel object is burned.
 19. A low pollution, high heat fuel for oxidation in a blast furnace in the from of solid objects comprising a compressed quantity of coke breeze and/or coal fines and/or revert material comprising molecular carbon attachment sites ionically non-phenolically polymerized together against blast furnace degradation by a long chain polymer free of a substance from which cyanide is derived, which object does not emit more than negligible amount of pollutants when the object is oxidized in a blast furnace.
 20. A method for manufacturing solid fuel shapes;(a) mixing carbon particles with a sufficient amount of water to form a reactive surface on the carbon particles having free carboxy ions; (b) reacting the reactive surface with a solution of resin dissolved in a hygroscopic solvent to free the ions on the surface of the carbon particles by exchange of the polymer for water which is adsorbed into the solvent, (c) forming under compression the resultant of (b) into solid shape, and (d) curing the solid shapes to form a long chain polymer reaction product of the carbon particles and the resin such that the solid fuel shapes that when combusted do not risk generation or release of hazardous substances.
 21. The method of claim 20 wherein the resin is chosen from the group consisting of styrene and acrylonitrile.
 22. The method of claim 20 wherein the hygroscopic solvent is methyl-ethyl-ketone.
 23. The method of claim 20 wherein the reactive surface is reacted with a solution of styrene resin and the hygroscopic solvent, and subsequently reacted with polyvinyl acetate emulsion.
 24. Solid fuel shapes that when combusted do not risk generation or release of a hazardous substance and which comprise a long chain polymer, the shapes produced by the method comprising;(a) mixing carbon particles with a sufficient amount of water to form a reactive surface on the carbon particles having free carboxy ions; (b) reacting the reactive surface with a solution of resin dissolved in a hygroscopic solvent to free the ions on the surface of the carbon particle by exchange of the polymer for water which is adsorbed into the solvent, (c) forming under compression the resultant of (b) into solid shape, and (d) curing the solid shapes to form a long chain polymer reaction product of the carbon particles and the resin to form the solid fuel shapes.
 25. The solid fuel shapes of claim 24 wherein the resin is chosen from the group consisting of styrene and acrylonitrile.
 26. The solid fuel shapes of claim 24 wherein the hygroscopic solvent is methyl-ethyl-ketone.
 27. The solid fuel shapes of claim 24 comprising the reaction product of carbon particles, styrene resin, and polyvinyl acetate. 